US11492510B2 - Protective graft coating for application onto polyurethane for chemical resistance, stain resistance, abrasion resistance and U.V. resistance - Google Patents
Protective graft coating for application onto polyurethane for chemical resistance, stain resistance, abrasion resistance and U.V. resistance Download PDFInfo
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- US11492510B2 US11492510B2 US15/625,076 US201715625076A US11492510B2 US 11492510 B2 US11492510 B2 US 11492510B2 US 201715625076 A US201715625076 A US 201715625076A US 11492510 B2 US11492510 B2 US 11492510B2
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- 0 *C.*C.*C.*OO.C.C=CC.CCC.CCCCCS.CCCS.CCCS.S.S.[H+].[H]S.[OH-] Chemical compound *C.*C.*C.*OO.C.C=CC.CCC.CCCCCS.CCCS.CCCS.S.S.[H+].[H]S.[OH-] 0.000 description 9
- QQONPFPTGQHPMA-UHFFFAOYSA-N C=CC Chemical compound C=CC QQONPFPTGQHPMA-UHFFFAOYSA-N 0.000 description 2
- YADZTANFOBBPCA-UHFFFAOYSA-N C=CC.C=CC.CC(=O)O.CCCC(C)COC(C)=O.CCCOC(C)=O.CCCOC(C)=O Chemical compound C=CC.C=CC.CC(=O)O.CCCC(C)COC(C)=O.CCCOC(C)=O.CCCOC(C)=O YADZTANFOBBPCA-UHFFFAOYSA-N 0.000 description 1
- SNEKAABSWLQQMX-UHFFFAOYSA-N C=CC.CCCC(C)(C)CC(C)(CCC)CC(C)(CC)CCC.CCCC(C)CC(C)CC.[H]C(C)CC([H])(C)CC([H])(C)C Chemical compound C=CC.CCCC(C)(C)CC(C)(CCC)CC(C)(CC)CCC.CCCC(C)CC(C)CC.[H]C(C)CC([H])(C)CC([H])(C)C SNEKAABSWLQQMX-UHFFFAOYSA-N 0.000 description 1
- GPRLSGONYQIRFK-UHFFFAOYSA-N CC(=O)O.CC(=O)[O-].[H+] Chemical compound CC(=O)O.CC(=O)[O-].[H+] GPRLSGONYQIRFK-UHFFFAOYSA-N 0.000 description 1
- SQANCALEKVCJAC-UHFFFAOYSA-N COC1OC(CO)C(C)C(O)C1O.[H]C(C)(C)CC.[H]N(C)C(C)=O Chemical compound COC1OC(CO)C(C)C(O)C1O.[H]C(C)(C)CC.[H]N(C)C(C)=O SQANCALEKVCJAC-UHFFFAOYSA-N 0.000 description 1
Classifications
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
- C09D175/00—Coating compositions based on polyureas or polyurethanes; Coating compositions based on derivatives of such polymers
- C09D175/04—Polyurethanes
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F299/00—Macromolecular compounds obtained by interreacting polymers involving only carbon-to-carbon unsaturated bond reactions, in the absence of non-macromolecular monomers
- C08F299/02—Macromolecular compounds obtained by interreacting polymers involving only carbon-to-carbon unsaturated bond reactions, in the absence of non-macromolecular monomers from unsaturated polycondensates
- C08F299/06—Macromolecular compounds obtained by interreacting polymers involving only carbon-to-carbon unsaturated bond reactions, in the absence of non-macromolecular monomers from unsaturated polycondensates from polyurethanes
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F299/00—Macromolecular compounds obtained by interreacting polymers involving only carbon-to-carbon unsaturated bond reactions, in the absence of non-macromolecular monomers
- C08F299/02—Macromolecular compounds obtained by interreacting polymers involving only carbon-to-carbon unsaturated bond reactions, in the absence of non-macromolecular monomers from unsaturated polycondensates
- C08F299/08—Macromolecular compounds obtained by interreacting polymers involving only carbon-to-carbon unsaturated bond reactions, in the absence of non-macromolecular monomers from unsaturated polycondensates from polysiloxanes
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G18/00—Polymeric products of isocyanates or isothiocyanates
- C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
- C08G18/08—Processes
- C08G18/0804—Manufacture of polymers containing ionic or ionogenic groups
- C08G18/0819—Manufacture of polymers containing ionic or ionogenic groups containing anionic or anionogenic groups
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G18/00—Polymeric products of isocyanates or isothiocyanates
- C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
- C08G18/28—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the compounds used containing active hydrogen
- C08G18/40—High-molecular-weight compounds
- C08G18/62—Polymers of compounds having carbon-to-carbon double bonds
- C08G18/6216—Polymers of alpha-beta ethylenically unsaturated carboxylic acids or of derivatives thereof
- C08G18/622—Polymers of esters of alpha-beta ethylenically unsaturated carboxylic acids
- C08G18/6225—Polymers of esters of acrylic or methacrylic acid
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G59/00—Polycondensates containing more than one epoxy group per molecule; Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L27/00—Compositions of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Compositions of derivatives of such polymers
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L27/00—Compositions of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Compositions of derivatives of such polymers
- C08L27/02—Compositions of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Compositions of derivatives of such polymers not modified by chemical after-treatment
- C08L27/12—Compositions of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Compositions of derivatives of such polymers not modified by chemical after-treatment containing fluorine atoms
- C08L27/18—Homopolymers or copolymers or tetrafluoroethene
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L75/00—Compositions of polyureas or polyurethanes; Compositions of derivatives of such polymers
- C08L75/04—Polyurethanes
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
- C09D127/00—Coating compositions based on homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Coating compositions based on derivatives of such polymers
- C09D127/02—Coating compositions based on homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Coating compositions based on derivatives of such polymers not modified by chemical after-treatment
- C09D127/12—Coating compositions based on homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Coating compositions based on derivatives of such polymers not modified by chemical after-treatment containing fluorine atoms
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
- C09D127/00—Coating compositions based on homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Coating compositions based on derivatives of such polymers
- C09D127/02—Coating compositions based on homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Coating compositions based on derivatives of such polymers not modified by chemical after-treatment
- C09D127/12—Coating compositions based on homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Coating compositions based on derivatives of such polymers not modified by chemical after-treatment containing fluorine atoms
- C09D127/16—Homopolymers or copolymers of vinylidene fluoride
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
- C09D133/00—Coating compositions based on homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides, or nitriles thereof; Coating compositions based on derivatives of such polymers
- C09D133/02—Homopolymers or copolymers of acids; Metal or ammonium salts thereof
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
- C09D151/00—Coating compositions based on graft polymers in which the grafted component is obtained by reactions only involving carbon-to-carbon unsaturated bonds; Coating compositions based on derivatives of such polymers
- C09D151/08—Coating compositions based on graft polymers in which the grafted component is obtained by reactions only involving carbon-to-carbon unsaturated bonds; Coating compositions based on derivatives of such polymers grafted on to macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
Definitions
- the invention relates to a method and a coating composition for application onto polyurethane to chemically graft a protective coating having improved physical properties of stain resistance, longer shelf life and improved UV resistance for use in the manufacture of seating systems and beds.
- the invention also relates to a method, coating and composition having an admixture of at least one monomer or prepolymer with fluropolymers, and particularly Fluro Prepolymer Lumiflor having superior characteristics or attributes for the healthcare or food industry environment such as hospitals and the like, where over time many of the exterior surfaces of beds, chairs and the like break down or become breeding grounds for bacteria, viruses and the like.
- Vinyl is commonly used in seating systems and other articles.
- a more durable alternative to vinyl is polyurethane but generally speaking polyurethane is a porous material and does not have sufficient stain, abrasion and chemical resistance.
- vinyl is commonly used in the healthcare environment such as hospitals or the like, as material for seating and beds.
- vinyl is easily punctured or torn and over time the exterior surface of vinyl beds and chairs break down, so as to provide areas where bacteria, viruses, bed bugs or the like can breed.
- the present invention relates to a chemical resistant grafted coating applied to polyurethane for use in seating, beds and other articles. It also relates to a method of grafting a protective coating on polyurethane parts for stain, abrasion and chemical resistance, water resistance and other adverse effects of the environment.
- this invention relates to a polymeric composition for application onto polyurethane for chemical resistance, abrasion resistance, stain resistance, water proof etc.
- the polyurethane does not have water proof, chemical resistance.
- the coating developed herein uses technology of chemical grafting that involves the use of prepolymers, monomers, catalyst, graft initiator, wetting agents, fillers and other ingredients of the composition. The coating thus obtained when applied on the polyurethane allows to obtain graft polymerization, thereby forming a polymeric film chemically attached to the substrate.
- the polyurethane substrate is reacted with graft initiator which creates the reaction sites on the substrate via free radical mechanism.
- Grafting by definition means to transplant or to be transplanted from one body to another in such a way that the new growth can continue.
- chemical grafting involves the transplantation of monomers to various substrates, to improve their positive properties without any basic change to the substrate itself.
- the invention as described herein uses monomers/prepolymers as grafting components and graft initiators to start and continue the grafting process.
- Chemical grafting on the other hand generally relates to chemical bonding and may be divided into three basic areas depending on their functional capability. They are:
- Coatings may be used to improve the appearance of the substrate, for corrosion protection, for electrical insulation, or adhering two materials together and the like. In each case, conventional coatings adhere to substrates by simple physical forces which can be easily broken, and consequently peeling or delamination may occur.
- coatings Since the attachment of coatings is accomplished by forming a chemical, covalent bond, much thinner coatings can provide extended life and superior adhesion.
- Successful grafting of a multitude of monomers and substrates such as metals, plastics, rubber, cellulosic materials, liquids and nature formed, living organisms can be accomplished.
- the chemical reaction that takes place on the surface provides a monomolecular layer of chemically bonded coating, which can be increased in thickness to the desired amount. Results have shown that coatings of 1 ⁇ 2 mil thickness can provide up to 2000 hours of salt spray protection.
- the fine layer of grafted material which can be easily deposited on the surface is not sufficient to alter and improve on the existing substrate.
- the monomers it is necessary for the monomers to penetrate into a certain depth or even throughout the matrix of the substrate to perform correctly. For example, to achieve total wettability of plastics such as porous Teflon, nylon and many others, one must be able to chemically graft water absorbing chemicals in depth. Similarly, to obtain permanent flame retardancy, one must totally penetrate a textile or a bundle of yarn filaments or even saturated wood.
- graft initiators which can be instrumental in grafting difunctional monomers in such a way that one of the carbon-carbon chains will attach itself to one of the substrates at temperature T 1 and the other end will follow suit at some temperature T 2 , higher than T 1 . It is known, that carbon-carbon chains are in the form of a helix, which can extend and contract depending on temperature.
- ABS acrylonitrile-butadiene-styrene
- Chemical grafting might be visualized as the growth of “whiskers” onto a material. These whiskers are joined to the substrate (basic material) by means of a chemical bond. This is in direct contradiction to ordinary coatings where the bond between the substrate and the coatings is only physical in nature. By chemical grafting a much higher degree of permanency is achievable.
- Chemical grafting involves the activation of the substrate. Once the substrate has been activated, chains of monomers linked by carbon bonds grow on the substrate.
- the present invention relates to a chemical resistant graft coating used on polyurethane for use in seating systems and other articles. It also relates to a method of grafting a protective coating in polyurethane parts for chemical resistance, water resistance and other adverse effects of the environmental condition of temperature, U.V. light, crocking along with excellent degree of abrasion resistance. Even when the polyurethane is coated with commercial coatings, they do not give the desired properties. These coatings adhere to the substrate through only physical bonds, they can be readily dislodged from the polyurethane substrate over a short period of time as moisture, oxygen and other corrosive gases permeate beneath the physically bonded polyurethane substrate. Thus, there is a need for a chemically bonded coating for polyurethane against abrasion, stain and U.V. resistance.
- U.S. Pat. No. 6,726,960 teaches a coated steel workpiece and a process for providing a steel workpiece with a coating of organic polymeric material, which comprises the steps of (i) applying to a surface of the workpiece a composition, comprising a) a polymerizable material that comprises at least one of epoxy prepolymers and urethane prepolymers; b) a monomer or prepolymer having at least one active group adapted to form graft polymerization linkages with the steel and with the polymerizable material containing hydroxyl, carbonyl, carboxyl, esters of carboxyl, amino, or epoxy group; c) catalytic initiator comprising ions of iron, silver, cobalt, or copper; and d) a peroxide; (ii) curing the resulting workpiece.
- a composition comprising a) a polymerizable material that comprises at least one of epoxy prepolymers and urethane prepolymers; b) a monomer
- the present invention is based on covering the polyurethane with a protective coating by chemically grafting organic monomers and prepolymers thereby forming a strong bonded polymeric film to the urethane substrate.
- the monomers/prepolymers are so selected that the polymeric film grafted onto polyurethane has excellent water proofing, abrasion, stain and U.V. and chemical resistance.
- the poly functional monomers and prepolymers are vinyl monomers, methacrylate monomers, urethane propolymers, acrylic prepolymers, styrene acrylic prepolymers, fluro polymers which are believed to be chemically bonded to the polyurethane substrate via amide hydrogen of urethane.
- the monomers are preferably acrylic, styrene acrylic, styrene butadiene, vinyl acrylic, or urethane having one or more hydroxyl, carboxyl and glycidyl group.
- It is another aspect of this invention to provide a method of grafting a coating onto a substrate comprising: a) preparing a mixture of (i) solvent including water (ii) a U.V. resistant compound (iii) a surfactant (iv) a monomer (b) mixing the mixture together (c) adding one by one and mix the following (v) urethane prepolymer (vi) fluro prepolymer (vii) water to define an admixture of monomers and prepolymers and (d) applying the admixture onto the substrate.
- Grafting by definition means to transport or to be transported from one body to another in such a way that the new growth can continue.
- chemical grafting involves the transplantation of monomers to various substrates, to improve their positive properties without any basic change to the substrate itself.
- graft initiators and chemical activators are a purely chemical way of exposing active sites on the surface of the substrate to initiate grafting. Application may be done by simply spraying, dipping or rolling.
- the surface preparation as well as grafting itself are performed in single application within a very reasonable time period. Since monomers are the building blocks of all polymers, they are very small in size and light in molecular weight compared with polymers, and what is generally most important is that they are much less expensive than polymers.
- the graft initiators and chemical activators to be described herein are a chemical way of exposing active sites on the surface of the substrate to initiate grafting. Application may be done by simply spraying, dipping or rolling, under atmospheric conditions.
- graft initiators permit, by adaptation, to graft an enormous variety of monomers to practically any imaginable substrate.
- the surface preparation as well as grafting itself are performed in a single application within a very reasonable time period. Since monomers are the building blocks of all polymers, they are very small in size and light in molecular weight, and what is important is that they are much less expensive than polymers.
- the “permanent” properties that can be added are nonflammability, abrasion resistance, soil repellency, improve adhesion ion-exchange, ultraviolet protection, water absorbency, gas impermeability, bactericidal, fungicidal and many others too numerous to list.
- the areas of application of the resultant materials include textiles, plastics, pollution control, biomaterials, etc.
- substrates which ordinarily would not be considered as possessing “active hydrogens” such as silicon, metals, polycarbonate can be utilized. In the latter situations sites for attachment are provided where possible by the removal of a hydrogen from the hydroxy form of a tightly bound oxide on the surface of the substrate or by the removal of labile electron which are available from the bulk of the material.
- the chemical grafting is consisted of growing polymer chains on a backbone chain of a substrate.
- the grafted polymer chains are formed from vinyl monomers, fluro monomers or monomers containing appropriate functionality, e.g. group such as acrylate, methacrylate, hydroxyl, carboxyl, epoxy, urethane, amide, amine, anhydride etc.
- the chemical activator has the capacity of removing these active hydrogens and concomitantly initiating the growth of polymer chains at the site from where the active hydrogen was removed.
- C.A. The chemical activator
- polypropylene this can be represented as follows:
- X can represent either a free radical, anion or cation, depending on whether the graft initiators (G.I.) removes a hydrogen and one electron, no electrons or two electrons, respectively. (There are a wide variety of monomers which do not lend themselves to the free-radical type of polymerization).
- substrates which ordinarily would not be considered as possessing “active hydrogens” such as silicon, metals, polycarbonate sites for attachment are provided, where possible, by the removal of a hydrogen from the substrate or by the removal of liable electrons which are available from the bulk of the material.
- Chemical grafting comprises growing polymer chains on a backbone chain of a substrate.
- the graft polymer chains are formed from vinyl monomers containing appropriate functionability, e.g. groups such as hydroxyl, carboxyl, epoxy, amide, amine, anhydride, etc.
- appropriate functionability e.g. groups such as hydroxyl, carboxyl, epoxy, amide, amine, anhydride, etc.
- This process may be terminated by radical combination.
- Reaction 6 especially should give a chemical bridge between the substrates,
- the side functional group .X could be chosen such that their further interaction with the substrate shall result into desired properties, e.g. adhesion, barrier properties and other characteristics.
- the graft initiator ion starts the action and the whole process behaves like an anticatalytic one.
- a small amount of graft initiator ion (5 to 10 ppm) is therefore sufficient to carry out the process of graft polymerization. All of the foregoing reactions take place in the presence of peroxide which concurrently regenerates the graft initiator forming a free radical.
- the free radical carbonyl group thereafter reacts with either a first component or a second component (e.g.
- the process may be terminated by radical combination.
- graft-initiation is portrayed as being separate and distinct from the subsequent graft-polymerization. For some applications this is the case. However, for a majority of the uses these steps can be combined due to the fact that the graft initiators possess sufficient selectivity such that almost no homopolymer is encountered.
- the rate of release of the desired species is governed by the kinetics for hydrolysis of classical esters and amides,
- quaternary-nitrogen-containing vinyl monomers are known or are readily available, e.g. benzyl 2-methyl-5-vinylpyridinium chloride,
- the desired species has any positive or negative polarity whatsoever, it can be attached to a substrate of opposite polarity. Also, the judicious selection of the polar monomer attached to the substrate would allow for different strengths of attachment and therefore subsequent release, should this be desirable.
- the desired species are held to the hydrogel by Van der Waal's forces.
- the activity of an enzyme for example can be maintained in this type of system because both its active site and its conformation is unaltered. Release of the desired species is diffusion controlled.
- Polyurethane may be defined as a polymer containing a plurality, carbonate linkages.
- the term polyurethane has also come to be used as a general name for the segment of the plastic industry which manufactures or uses polyisocyanates.
- a foundation of the polyurethane industry is the isocyanate.
- the physical form and properties of the polymer can also be tailored by selecting from among a broad range of monomers or attaching monomers by chemical grafting.
- polyurethanes Generally speaking the chemical and structural diversity of the diverse materials that are called polyurethanes is broad so that it is difficult to describe them in terms of nominal or average properties. Combinations of properties that compare very favourably with those of engineering resins or monomers can be obtained with isocyoanate based polymers.
- Key polyurethane markets and applications include building and construction appliances, transportation, composite wood, recreation equipment, furnishings, coatings, adhesives, sealants elastomers, marine, medical and apparel.
- Polyurethanes can be found in virtually any industry where performance is critical, whether it is through safe guarding efforts of protective coatings. Polyurethane coatings and sealants protect bridges, cars, airplanes etc. Polyurethanes should be the material of choices for applications needing designs freedom and dependable performance. Outdoor and recreation applications will continue to benefit from polyurethane's unique engineered characteristics. innovative applications will also be found globally in high-tech medical instruments, hospitals and pharmaceutical labs from treatment of trolleys to operating microscopes.
- the invention described herein can be applied to any number of polyurethane parts to toughen the surface.
- the invention has particular application to the hospital environment where the surface of beds or chairs are routinely cleaned and sanitized. However over time many of the exterior surface of chairs, beds or the like break down or become cracked, which become breeding grounds for bacteria, viruses and the like to grow.
- the surface of such chairs, armrest, beds or the like in some cases are comprised of polyurethane.
- the polyurethane may be a solid continuous surface. In other cases the surface may be comprised of a different material, such as, nylon or vinyl or the like where a polyurethane coating is applied thereon. In each of these cases there is a polyurethane substrate.
- the methods require a grafting solution comprised of water, a catalyst for activating a graft initiator, a graft initiator which renders the substrate receptive to chemical grafting or bonding.
- the grafting solution also includes at least one monomer or prepolymer or an admixture thereof.
- a monomer is a component having a molecular weight of less than 1200. It is especially preferred that at least one monomer has a molecular weight of from about 200 to 800. The prepolymer would have a molecular weight that would be greater than 1200.
- the graft solution includes a graft initiator in order to provide an active site on the substrate for reaction.
- the graft initiator is selected to abstract an active hydrogen as previously described.
- the initiator is a metal ion provided by the ionization of a metal salt.
- a salt such as a silver nitrate is utilized to activate the graft initiator such salts are preferably present in the graft solution in an amount from about 0.001% to about 0.01% by weight of the solution.
- the graft solution includes a catalyst in order to ionize the metal salts to provide an activating ion.
- a catalyst in order to ionize the metal salts to provide an activating ion.
- a wide variety of catalysts may be utilized in the method of the present invention including peroxide, peracid or a perbenzoate. Peroxide catalysts of urea, hydrogen and benzoyl peroxides are especially preferred.
- the catalyst is also present in a small amount.
- the grafting solution comprises 0.001 to about 0.01% weight of the catalyst.
- the grafting solution would comprise an effective weight percentage of monomer and or prepolymer to provide a tough protective coating having a selected abrasion resistance.
- the grafting solution comprises from about 40 to 50 percent solids in an aqueous solution.
- the protective surface comprises the chemically bonded monomer or prepolymer bonded to the polyurethane substrate backbone.
- a requisite amount of different precalculated quantity of styrene acrylic prepolymers, urethane prepolymers, epoxy prepolymers, acrylic prepolymers, pigments, coupling agents, thickeners, monomers surfactants, water, solvent, catalyst and graft initiator were taken in a container.
- the coating solution thus prepared is ready for application on the polyurethane substrate.
- the coating formulation thus prepared is applied to the polyurethane substrate by spraying or any other convenient method.
- the coated polyurethane is air dried for 10-15 minutes and subjected to cure at 125-150° C. for 5-10 minutes.
- the following represent some examples and are not limiting. In other words it is possible to vary some of the ingredients and still obtain the desired results. Again as an example some of the ingredients may be changed by +/ ⁇ 15% or +/ ⁇ 10% and still obtain the desired results.
- the chemical by weight referred to above can vary up to +1-15%
- the chemical by weight referred to above can vary up to +/ ⁇ 15%. Generally speaking if more of a chemical is added relative the water the thicker, or more viscous the application.
- the chemical by weight referred to above can vary up to +/ ⁇ 15%. Generally speaking if more of a chemical is added relative the water the thicker, or more viscous the application.
- chemical and abrasion resistant urethane seats are produced which are better than the conventional product, having improved UV resistance and a composition having improved shelf life.
- the resulting article or part also exhibits improved physical properties and an enhanced ability to withstand staining and improved U.V. resistance as compared to the prior art and as compared with applicant's US Published 2014/0335362.
- the resulting coating layer admixture of the prepolymer and monomer can be varied depending on how far the reaction is carried out.
- the graft solution includes water, a graft initiator for activating sites on the polyurethane, a catalyst for activating or regenerating the graft initiator and a first component that has a functional group for reaction and covalent bonding with an active site for the substrate. If preferred it can be a water dispersible polymer such as for example an epoxy prepolymer, a urethane prepolymer and acrylic prepolymer.
- components comprises at least one water dispersible polymer which included at least one functional group, e.g.—a carboxyl, hydroxyl, epoxy, amino, melamine, fluro or acrylic group.
- functional group e.g.—a carboxyl, hydroxyl, epoxy, amino, melamine, fluro or acrylic group.
- These polymers are ideally suited for incorporation into grafting solutions; have sufficient graft segments so as to have a highly flexible graft polymer.
- the monomers can be an acrylate, methecrylate or urethane acrylate.
- Coatings provide protection according to mechanisms.
- the First mechanism is impermeability.
- the coating must be inert to chemical and impervious not only to air, oxygen, water and carbon dioxide, but also to the passage of ions and electrons. It also must have good adhesion. Such coating prevents abrasion by suppressing the process and chemical graft is superior to ordinary coating and gives chemical and abrasion resistance particularly in the healthcare environment.
- Acrylic and diacritic monomers having functional group such as carboxyl, hydroxyl, amino or ester are preferred.
- a metallic salt such as silver nitrate, silver perchlorate, ferrous ammonium sulfate, silver acetate
- Graft initiators are used in small quantities in order to ionize the metal salt to provide an activating metal ion
- the graft solution includes a catalyst.
- catalysts may be utilized in the present invention. Peroxide of urea, hydrogen, and benzyl are used in most of the water based reactions. The catalyst functions to ionize metal salts into silver and iron or any other metal as graft initiator.
- This invention has particular application to furniture in hospitals and especially for chairs and beds.
- the coating described can be sprayed over the seat including under the seat and over the seams so as to make the seat seamless and sealed with a tough outer surface that is difficult to puncture, chemically resistant, and resistant to abrasion.
- the under surface of the seats can include brackets or clips (that are also sprayed with the coating) that engage with the frame of the chair so that the seat can be easily removed or popped off for cleaning and the seamless aspect of the seat can be maintained.
- chairs and beds in either hospital or hotel settings can have the outer surface or substrate made with the composition described so that the mattresses and seat cushions are sealed and seamless. This is highly desirable to combat bedbug infestations in hospitals and hotels as the treated surface will inhibit the infestation of these pests and prevent the spread of infection.
- the invention described herein can be used on a variety of other articles such as anti-fatigue mats, commodes, mattresses and wheelchair cushions.
Abstract
Description
GI+ROOH→RO+OH−+GI+
PARTS BY | |
FORMULATION | WEIGHT |
Bulyt Carbitol | 40.00 |
EEP Solvent | 20.00 |
Antioxidant Irganox 1010 | 0.08 |
U.V. Absorbent Tinuvin 292 | 0.08 |
Non Ionic Surfactant Triton X-100 | 2.00 |
Monomer Coatosil 1770 | 8.00 |
Water | 200.00 |
Flattening Agent Dapro FA-34 | 16.00 |
-- Mix the above together then add one by one and mix the following . . . |
Silica modified Acrylic Prepolymer Chemtan AC-1 | 200.00 |
Urethane Prepolymer Urotuf W 38 | 120.00 |
Fluro Prepolymer Lumiflon FE 4300 | 80.00 |
Fluro Propolymer Lumiflon FE 4400 | 80.00 |
Acrylated Polyvinylidene Fluroide Prepo, | |
Kynar Aquatic ARC | 160.00 |
Acrylic Emulsion API 296 E | 24.00 |
Fluro Dispersion AQ 50 | 20.00 |
Melamine Prepolymer Cymel 385 | 24.00 |
Water | 120.00 |
Urethane Acrylate SR 9035 | 4.00 |
Dodecyl Benzene Sulfonic Acid Nacure 5225 | 1.00 |
Urea Peroxide 1.00% Solution in Water | 0.20 |
Silver Perchlorate 0.1% Solution in Water | 0.2 |
PARTS BY | |
FORMULATION | WEIGHT |
Bulyt Carbitol | 10.00 |
EEP Solvent | 5.00 |
Antioxidant Irganox 1010 | 0.20 |
U.V. Absorbent Tinuvin 292 | 0.20 |
Non Ionic Surfactant Triton X-100 | 0.50 |
Monomer Coatosil 1770 | 2.00 |
Monomer Silane A171 | 0.50 |
Flattening Agent Dapro FA-34 | 5.00 |
-- Mix the above together then add one by one and mix the following . . . |
Silica modified Acrylic Prepolymer Chemtan AC-1 | 54.00 |
Fluro Prepolymer Lumiflon FE4300 | 30.00 |
Fluro Propolymer Lumiflon FE4400 | 25.00 |
Acrylated Polyvinylidene Fluride Prepo, Kynar Aquatic | 30.00 |
ARC | |
Silicon Modified Chemtan FA-22 | 04.00 |
Fluro Dispersion AQ 50 | 10.00 |
Melamine Prepolymer Resimene 717 | 06.00 |
Water | 80.00 |
Urethane Acrylate SR 9035 | 4.00 |
Fluro Emulsion Rainoff FC-6 | 10.00 |
Urea Peroxide 1.00% Solution in Water | 0.20 |
Silver Perchlorate 0.1% Solution in Water | 0.20 |
PARTS BY | |
FORMULATION | WEIGHT |
Bulyt Carbitol | 10.00 |
Antioxidant Irganox 1010 | 0.08 |
U.V. Absorbent Tinuvin 292 | 0.08 |
Non Ionic Surfactant Triton X-100 | 2.00 |
Monomer Coatosil 1770 | 8.00 |
Dispersing Agent Irgosperse 2176 | 2.00 |
Water | 200.00 |
Flattening Agent Dapro FA-34 | 16.00 |
-- Mix the above together then add one by one and mix the following . . . |
Silica modified Acrylic Prepolymer Chemtan AC-1 | 20.00 |
Urethane Prepolymer Neopac E125 | 40.00 |
Fluro Prepolymer Lumiflon FE 4300 | 80.00 |
2% Solution of FC 4430 in Water | 2.00 |
Acrylic Emulsion API 296 E | 24.00 |
Fluro Dispersion AQ 50 | 10.00 |
Melamine Prepolymer Resimene AQ7551 | 20.00 |
Water | 120.00 |
Urethane Acrylate SR 9035 | 4.00 |
Urea Peroxide 1.00% Solution in Water | 0.20 |
Ferrons Amm. Sulfate 0.1% Solution in Water | 0.20 |
Claims (15)
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
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US15/625,076 US11492510B2 (en) | 2017-06-16 | 2017-06-16 | Protective graft coating for application onto polyurethane for chemical resistance, stain resistance, abrasion resistance and U.V. resistance |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US15/625,076 US11492510B2 (en) | 2017-06-16 | 2017-06-16 | Protective graft coating for application onto polyurethane for chemical resistance, stain resistance, abrasion resistance and U.V. resistance |
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US20180362800A1 US20180362800A1 (en) | 2018-12-20 |
US11492510B2 true US11492510B2 (en) | 2022-11-08 |
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US20210041331A1 (en) * | 2019-08-09 | 2021-02-11 | Crescent Manufacturing Company | Cutting blades |
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CN112409867A (en) * | 2020-11-11 | 2021-02-26 | 惠州市惠阳区嘉泰涂料有限公司 | Water-based wear-resistant paint and preparation method thereof |
CN114230732B (en) * | 2021-12-30 | 2022-12-02 | 华中科技大学 | Method for chemically grafting hydrophobic polymer and hydrogel layer |
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